Force connection strut

ABSTRACT

A connection strut of a chassis of a passenger car or utility vehicle for the connection between the chassis and the wheel carrier, preferably an axle strut or a chassis control arm, with an elongated basic body and at least two mount supports arranged at the end for introducing and leading out forces. The basic body has a composite between a flat metal insert and a plastic structure forming the rest of the contour. The plastic structure is formed by encasement of the metal insert. The rest of the contour is defined here as the difference between the final contour of the force connection strut and the portion that is formed by the metal insert.

[0001] Force connection strut of a chassis of a passenger car or utility vehicle.

[0002] The present invention pertains to a force connection strut of a chassis of a passenger car or utility vehicle for connection between the chassis and the wheel carrier, preferably an axle strut or a chassis control arm, with an elongated basic body and at least two mount supports arranged at the end for introducing and leading out forces.

[0003] Such chassis parts are generally known. Reference is made as an example to the documents DE 41 20 772 C2, DE 33 32 771 C2 and DE 199 31 079 A1.

[0004] The above-mentioned documents pertain to force-transmitting chassis parts, which comprise essentially an elongated basic body and mount supports arranged at the end with mounts. Even though the mount supports and mounts are made in these cases of composite materials, i.e., a combination of metals and plastic components, the elongated basic body consistently consists of metal.

[0005] It was found in the course of the development that the said chassis parts, whose basic body is made mostly from forged steel or gray cast iron, do not meet the increased requirements concerning the characteristics of the materials, and the possibilities are also exhausted concerning weight reduction in the case of all-metal basic bodies.

[0006] An all-plastic basic body is sometimes also used instead of an all-metal basic body to optimize the weight, but such chassis parts made of plastic inherently have the problem that these plastics usually tend to undergo brittle fracture if they have the sufficient strength properties. This means that the function of these chassis parts is lost 100% after damage to such a chassis part, whereas a complete loss of function does not occur in the case of chassis parts made of metal, even though bending and deformation develop.

[0007] Even though composite materials based on sheet metal-plastic combinations in the manufacture of automobiles have been known from the literature, e.g., from the Offenlegungsschrift DE 38 39 855 A1, the applications proposed there are structural parts for motor vehicle doors, shock absorbers, supports, front and rear shells or door sills, in which the sheet metal parts which determine the outer shape are said to have increased strength or rigidity due to plastic ribbing. None of these lightweight components proposed is, however, suitable for absorbing massive compressive/tensile forces as they occur in chassis parts.

[0008] The object of the present invention is therefore to develop a force connection strut of a chassis for a passenger car or utility vehicle, which has, on the one hand, the advantages of plastic elements in terms of weight, but, on the other hand, does not suffer an immediate total loss of its functionality even in case of damage.

[0009] This object is accomplished by the features of the independent patent claim. Advantageous variants of the present invention are the subject of subclaims.

[0010] Accordingly, the inventors propose that the prior-art force connection strut of a chassis of a passenger car or utility vehicle for the connection between the chassis and the wheel carrier, preferably an axle strut or a chassis control arm, with an elongated basic body and at least two mount supports arranged at the end for introducing and leading out forces be improved such that the basic body has a composite between a flat metal insert and a plastic structure forming the rest of the contour, which said plastic structure is formed by encasing the metal insert. The rest of the contour is defined here as the difference between the final contour of the force connection strut and the portion that is formed by the metal insert.

[0011] This combination in a force connection strut now makes it possible, on the one hand, to utilize the advantages of a plastic structure and to achieve a considerable weight reduction along with high strength, while, on the other hand, it is ensured by the metal insert that no immediate 100% loss of function will develop even in case of damage.

[0012] Another advantage is that the manufacture of relatively complex plastic structures can be carried out in a substantially simpler manner than that of all-metal structures. For example, a highly complex shape with a broad scope of function can be produced here [with] a very simply structured metal insert prepared here by means of encasement with a plastic.

[0013] It is advantageous here for the metal insert to be shaped such that it is used in its extension essentially for absorbing compressive/tensile forces, while the plastic structures are subjected predominantly to torsion.

[0014] In an advantageous embodiment of the force connection strut according to the present invention, the force connection strut has a T-shaped or L-shaped cross section with two legs in the area of the basic body.

[0015] In an especially advantageous embodiment of the force connection strut according to the present invention, the force connection strut has an H-shaped or U-shaped cross section with three legs in the area of the basic body.

[0016] This force connection strut may be designed, e.g., such that at least one leg, preferably the centrally located leg, is reinforced by at least one metal insert and is preferably formed by the said metal insert. The central leg is defined here as the leg that is arranged between two other—peripheral—legs.

[0017] In another embodiment of the force connection strut, at least two legs, preferably the peripherally located legs, are reinforced by at least one metal insert each and are preferably formed by the said metal insert. However, it is also possible in this variant to reinforce only one of the peripherally located legs with a metal insert, whereas another leg, lying at right angles thereto, is likewise reinforced, and the second peripherally located leg is made exclusively of plastic.

[0018] If an especially high load-bearing capacity and also a high level of residual function after damage are desired, it is possible to reinforce all legs with at least one metal insert each or preferably to form all legs from such a metal insert, but no metallic connection is preferably provided between the individual metal inserts in this case.

[0019] If the rigidity, especially the torsional rigidity, is to be improved, it is advantageous to provide cross webs, preferably such made of a plastic, in the area of the basic body. It is also possible due to such a design to make individual legs as perforated legs, so that it is possible to additionally reduce the weight.

[0020] Concerning the plastics used, it is also possible to use fiber reinforcements, besides the homogeneous plastic, preferably using glass fibers, carbon fibers or aramide fibers in this case. Such designs with fiber reinforcement in the plastic may be advantageously selected to be such that the percentages of fiber make it possible to extensively adapt the thermal expansion characteristics of the plastic structures to the thermal expansion characteristics of the at least one metal insert at least in the range of the operating temperatures.

[0021] Due to this special design, the expansion characteristic of the plastic structures can be adapted to the expansion characteristics of the metal inserts, so that fatigue phenomena, cracking or separation between the metal and the plastic do not develop even in the case of frequent temperature changes.

[0022] Since plastics are especially suitable for preparing more complex outer shapes, especially in the case of the use of injection molding methods, the inventors also propose that the outer shape of the force connection strut be defined exclusively by the plastic structure. It is possible as a result, on the other hand, to use simple and easy-to-manufacture structures concerning the metal inserts.

[0023] Furthermore, the mount supports arranged at the end can be manufactured from plastic, but mount supports that have a metal insert are possible as well. The metal inserts may be preferably designed such that the mount support including the mount optionally arranged therein pass through this at the end. Since especially strong forces must be absorbed in this end area, and the material is additionally reduced by the mount support, it may be especially advantageous for the metal insert to have a thickening at the end on at least one side, which is prepared, e.g., by means of material layers applied additionally, which are connected to each other as rigidly as possible.

[0024] The suitable metal insert is made especially of steel, an alloy based on iron or, if an especially lightweight design is important, also aluminum or aluminum alloys.

[0025] If the metal insert is exposed to special environmental conditions, it may be advantageous to apply a corrosion-inhibiting surface protection, and if the outside is unprotected, especially this outside should be coated.

[0026] To prevent cracking in the plastic, the metal insert should, in addition, be deburred.

[0027] Furthermore, it is proposed that to improve the stability, the metal insert may have beads. As a result, this leads to an improvement in the stability of the metal insert itself, on the one hand, and in the connection between the metal structure and the plastic structure, on the other hand.

[0028] In addition, openings may be provided in the metal inserts for reasons of weight reduction and to improve the connection action between the metal and the plastic.

[0029] It is also especially favorable for all metal inserts as a whole to be completely surrounded by plastic, because this counteracts the development of corrosion in the area of the metal especially effectively.

[0030] In special embodiments of the metal inserts, the end surfaces may form an angle with each other, and they may be preferably arranged at right angles to each other. It is possible to manage the forces acting differently at the respective ends of the force connection strut especially well.

[0031] Provisions are made in another special embodiment of the force connection strut according to the present invention for at least one mount support to have a metal sleeve. The elasticity of such a mount support is improved by this metal sleeve. The metal sleeve may, e.g., also have openings, so that an especially rigid connection is obtained between the metal structure and the plastic structure.

[0032] The mount support of the force connection strut according to the present invention advantageously has, on the whole, a cylindrical shape, which is preferably provided with a thickening at the end. In addition, the mount support may also have a radial contraction, so that better seating, e.g., of a molecular bearing, is guaranteed.

[0033] For example, molecular bearings, ball bearings or even fixed bearings may be used as the bearings, their embodiment depending on the particular intended use.

[0034] The present invention will be described in greater detail below on the basis of the preferred exemplary embodiments with reference to the figures. Specifically,

[0035]FIG. 1a shows a top view of the axle strut with a metal insert;

[0036]FIG. 1b shows a cross section through the axle strut from FIG. 1a;

[0037]FIG. 1c shows a side view of the axle strut from FIG. 1a;

[0038]FIG. 2a shows a top view of a bent axle strut with a metal insert;

[0039]FIG. 2b shows a cross section through the axle strut from FIG. 2a;

[0040]FIG. 2c shows a side view of the axle strut from FIG. 2a;

[0041]FIG. 3a shows a top view of a straight axle strut with a twisted metal insert;

[0042]FIG. 3b.i shows a section A-A through the axle strut from FIG. 3a;

[0043]FIG. 3b.ii shows a section A′-A′ from FIG. 3a;

[0044]FIG. 3b.iii shows a section A″-A′ from FIG. 3a;

[0045]FIG. 3c shows a side view of the axle strut from FIG. 3a;

[0046]FIG. 4a shows a top view of the axle strut with metal inserts in the peripheral legs;

[0047]FIG. 4b shows a cross section through the axle strut from FIG. 4a;

[0048]FIG. 4c shows a side view of the axle strut from FIG. 4a;

[0049]FIG. 5 shows a top view of the axle strut with metal inserts in the peripheral legs and ribbed and interrupted central leg;

[0050]FIG. 6a shows a top view of a metal insert with a thickening at the end;

[0051]FIG. 6b shows a side view of a metal insert with a thickening at the end;

[0052]FIG. 7 shows a longitudinal section through an axle strut with longitudinal struts arranged in an X-shaped pattern with metal inserts;

[0053]FIG. 8a shows a top view of a bent axle strut with a metal insert on one side, which wraps around mount supports; and

[0054]FIG. 8b shows a section A-A through the axle strut from FIG. 8a.

[0055]FIGS. 1a through 1 c show different views of an axle strut according to the present invention for a truck. The axle strut 1 has a contour with an H-shaped cross section with a central leg 2 and two peripheral legs 3 and 4 connected thereto. A metal insert M, which is completely surrounded by plastic, is located in the central leg 2, and the said plastic also defines the overall contour of the axle strut and thus also forms the two peripheral legs 3 and 4 of the basic body G. A mount support 5 each is located at both ends of the basic body G, and the said mount support likewise consists of plastic and its outer shape corresponds to a cylinder and has a contraction 6 on the inside. An elastically damping molecular bearing with a journal 7 is inserted into the mount support 5.

[0056] The axle strut 1 can be manufactured by punching the metal insert out of a flat sheet metal, but careful deburring of the edges shall be ensured to prevent the edges from damaging the plastic structure during the loads occurring later. This sheet metal is subsequently encased on all sides according to the injection molding process with plastic, preferably with a plastic with fiber insert, and it thus forms the final shape of the axle strut 1.

[0057]FIGS. 2a through 2 c correspond basically to the views in FIGS. 1a through 1 c, but the axle strut being shown here has a curvature in the plane of the central leg 2. This axle strut also has an H-shaped cross section and its design corresponds to that of the axle strut in FIGS. 1a through 1 c with the exception of the curvature.

[0058] Another variant of an axle strut with a single metal insert is shown in FIGS. 3a through 3 c. This is an axle strut 1, which has a twisting by 90° in the area designated by “10” in the basic body G. The mount support 5 disposed at the end with the molecular bearing 9 contained therein and with the journals correspond to the designs of the axle struts shown above, but are offset by 90° in relation to one another.

[0059]FIGS. 3b.i, 3 b.ii and 3 b.iii show the sections A-A, A′-A′, A″-A″ from FIG. 3a. These figures show the continuous transition of the metal insert M with a twist or torsion by 90°, while the profile also changes correspondingly initially from an H-section via a box section to an H-section, but with a 90° rotation in relation to the first H-section.

[0060] Another embodiment variant of the axle strut 1 according to the present invention is shown in a top view, as a cross section and as a side view in FIGS. 4a through 4 c, respectively. The cross section, which is shown in FIG. 4b, is likewise H-shaped in this embodiment, but the metal insert is inserted this time in the two peripheral legs 3 and 4, so that the mount supports are enclosed in the entire axle strut in a substantially more stable manner due to the said legs surrounding the mount support 5 at the end, which makes possible a substantially better force transmission.

[0061]FIG. 5 shows a variant of the axle strut from FIG. 4a, wherein the central leg 2, which is made of plastic, is provided with perforations 12 and webs 11 disposed between them here. The weight is thus reduced compared with the embodiment described previously.

[0062] For axle struts subject to special loads, it is possible to prepare an additional thickening V in the metal insert. This is shown, e.g., in FIGS. 6a and 6 b. FIG. 6a shows a top view of a metal insert M, which is reinforced by metal inserts applied additionally in the end area. FIG. 6b shows a side view of this metal insert M with the thickenings V on both sides.

[0063] Instead of the thickening with multiple layers, which is being shown here, it is also possible to manufacture the metal insert from so-called “tailored blanks” or “tailored strips.” The areas of the metal insert that are subject to a high load may be made of thicker sheet metal parts and areas subject to lower load may be made from thinner sheet metal parts here, which are welded together to form the entire metal insert.

[0064] Another possible embodiment of a force connection strut 1, e.g., of an axle strut of a chassis, is shown as a longitudinal section in FIG. 7. This figure shows an embodiment in which an H-section arranged at the end converges toward the middle with the two peripheral legs 3 and 4, while the central leg 2 tapers toward the middle and disappears in the middle itself. Both peripheral legs 3 and 4 contain a metal insert M each, which extends up to and around the mount support 5.

[0065] Finally, FIG. 8a shows a schematic top view of a bent force connection strut, where a metal strip is used as the metal insert M, the said metal strip first surrounding the left-hand mount support, beginning at one end, then extends through the first bent peripheral leg 3 and finally surrounds the second mount support on the right-hand side. The outer contour is formed by the plastic encasement around the metal insert in this case as well, and the metal insert ensures that a minimum of functionality is nevertheless preserved even in case of a brittle fracture in the area of the plastic structure. The metal insert consequently forms a tough skeleton within a plastic structure.

[0066] This design is shown once again in FIG. 8b in a section A-A from FIG. 8a. It can be clearly recognized here how the first of the two peripheral legs 3 and 4, which surround the central leg 2, is reinforced in the H-shaped cross section with the metal insert (M), which is a flexible strip.

[0067] It should also be noted that the openings in the metal inserts—with the exception of the embodiment shown in FIGS. 8a and 8 b—can be prepared to receive the sleeve and to form the mount support both by simply punching out a hole and by deep drawing and forming an indentation, into which a sleeve can be inserted, or by directly forming a shape that itself corresponds to a sleeve.

[0068] On the whole, it is achieved through the design of force connection struts according to the present invention that a substantial weight reduction is achieved, on the one hand, but a 100% loss of the functionality of the force connection strut does not occur immediately at the same time even in case of damage, because the metal insert(s) present offer(s) an additional safety against brittle fracture.

List of Reference Numbers

[0069]1 Axle strut

[0070]2 Central leg

[0071]3 First peripheral leg

[0072]4 Second peripheral leg

[0073]5 Mount support

[0074]6 Contraction

[0075]7 Journal

[0076]8 Opening in the metal insert

[0077]9 Molecular bearing

[0078]10 Connection area

[0079]11 Plastic webs

[0080]12 Opening

[0081] M Metal insert

[0082] K Plastic

[0083] V Thickening

[0084] G Basic body 

1. Said force connection strut (1) of a chassis of a passenger car or utility vehicle for connection between a chassis and a wheel carrier, preferably an axle strut or chassis control arm, with a said elongated basic body (G) and at least two said mount supports (5) arranged at the end for introducing and leading out forces, characterized in that the said basic body (G) has a composite of at least one said flat metal insert (M) and a said plastic structure (K) forming the rest of the contour, which is formed by the at least partial encasement of the said metal insert (M).
 2. Force connection strut in accordance with patent claim 1 above, characterized in that the said metal insert (M) is shaped such that it is used over its extension essentially to absorb compressive/tensile forces and the said plastic structures (K) are used to absorb torsion.
 3. Force connection strut in accordance with one of the patent claims 1 through 2 above, characterized in that it has a T-shaped or L-shaped cross section with two said legs in the area of the said basic body (G).
 4. Force connection strut in accordance with one of the patent claims 1 through 2 above, characterized in that it has an H-shaped or U-shaped cross section with three said legs (2, 3, 4) in the area of the said basic body (G).
 5. Force connection strut in accordance with patent claim 4 above, characterized in that at least one said leg, preferably the said centrally located leg (2), is reinforced by at least one said metal insert (M), and is preferably formed by same.
 6. Force connection strut in accordance with patent claim 4 above, characterized in that at least two said legs, preferably said, peripherally located legs (3, 4), are reinforced by at least one said metal insert (M) each and are preferably formed by same.
 7. Force connection strut in accordance with patent claim 4 above, characterized in that all said legs (2, 3, 4) are reinforced by at least one said metal insert (M) each and are preferably formed by same, but have no metallic connection among each other.
 8. Force connection strut in accordance with one of the patent claims 1 through 7 above, characterized in that said cross webs (11), preferably ones made of plastic, are provided in the area of the said basic body (G).
 9. Force connection strut in accordance with one of the patent claims 1 through 8 above, characterized in that the plastic used has at least some fiber reinforcements, preferably reinforcements consisting of glass fibers, carbon fibers or aramide fibers.
 10. Force connection strut in accordance with patent claim 9 above, characterized in that the percentages of fiber are selected to be such that the thermal expansion characteristics of the said plastic structures (K) correspond at least extensively to the thermal expansion characteristics of the said, at least one metal insert (M) in the range of the operating temperatures.
 11. Force connection strut in accordance with one of the patent claims 1 through 10 above, characterized in that the outer shape is determined exclusively by the said plastic structure (K).
 12. Force connection strut in accordance with one of the patent claims 1 through 11 above, characterized in that at least one and preferably both said mount supports (5) arranged at the end consist(s) of plastic.
 13. Force connection strut in accordance with patent claim 12 above, characterized in that at least one said mount support (5) including the mount that may be arranged therein passes through at least one said metal insert (M).
 14. Force connection strut in accordance with one of the patent claims 1 through 13 above, characterized in that at least one said metal insert (M) has, at least on one side, a said thickening (V) arranged at the end, preferably a said thickening formed by additional material layers.
 15. Force connection strut in accordance with one of the patent claims 1 through 14 above, characterized in that at least one said metal insert (M) consists of steel or an iron-based alloy.
 16. Force connection strut in accordance with one of the patent claims 1 through 15 above, characterized in that at least one said metal insert (M) consists of aluminum or an aluminum alloy.
 17. Force connection strut in accordance with one of the patent claims 1 through 16 above, characterized in that at least one said metal insert (M) has a corrosion-inhibiting surface protection, at least on an unprotected outer side.
 18. Force connection strut in accordance with one of the patent claims 1 through 17 above, characterized in that the at least one said metal insert (M) is deburred.
 19. Force connection strut in accordance with one of the patent claims 1 through 18 above, characterized in that the at least one said metal insert (M) has beads.
 20. Force connection strut in accordance with one of the patent claims 1 through 19 above, characterized in that the at least one said metal insert (M) has openings.
 21. Force connection strut in accordance with one of the patent claims 1 through 20 above, characterized in that all said metal inserts (M) are completely surrounded by plastic.
 22. Force connection strut in accordance with one of the patent claims 1 through 21 above, characterized in that the surfaces of the at least one said metal insert (M), which said surfaces are arranged at the end, form an angle with one another and are preferably arranged at right angles to one another.
 23. Force connection strut in accordance with one of the patent claims 1 through 22 above, characterized in that at least one said mount support (5) has a metal sleeve.
 24. Force connection strut in accordance with patent claim 23 above, characterized in that at least one of the said metal sleeves has openings.
 25. Force connection strut in accordance with one of the patent claims 1 through 24 above, characterized in that at least one said mount support (5) has a cylindrical shape, preferably with at least one said thickening arranged at the end.
 26. Force connection strut in accordance with one of the patent claims 1 through 25 above, characterized in that at least one said mount support (5) has a said inner radial contraction (6).
 27. Force connection strut in accordance with one of the patent claims 1 through 26 above, characterized in that a said molecular bearing (9) or a ball bearing or a fixed bearing is provided in at least one said mount support (5).
 28. Force connection strut in accordance with one of the patent claims 1 through 27 above, characterized in that the said metal insert consists of tailored blanks or tailored strips, made preferably from sheet metals of different thicknesses. 